Rising expanse of global human population is providing substantial stimulus to the construction of structures that can meet the surging residential and commercial needs. Expecting industrial structures and buildings to remain strong and dependable while bearing the redundant weight of millions of people has put larger impetus on welding technologies used in timely repairs. Newer advancements in welding repair work have fuelled the demand for welding consumables such as flux-cored wires, solid wires, fluxes, stick electrodes, and submerged arc welding (SAW) wires.
As a result, the global market for welding consumables is projected to exhibit significant growth, attaining an estimated market value of US$ 11.8 Bn by the end of 2016. The demand for such welding consumables is considerably influenced by growing adoption of prominent welding technologies. Laser beam welding and ultrasonic welding are relatively advanced welding technologies, while resistance welding and oxy-fuel welding are regarded as the conventional methods. Nonetheless, the most prominently-used form of welding technology remains to be identified as arc welding.
What is Arc Welding?
In arc welding, an electric arc is created between the welding electrode and the base materials. Filler metals are used as welding consumables, and are melted with welding power supply to fix the structural ruptures. Arc welding uses consumable as well as non-consumable welding electrodes, and efficiently runs on both; direct (DC) and alternating current (AC). Furthermore, arc welding techniques are categorised in semi-automatic, manual and fully-automatic. The global welding consumables market is expected to account for over 40% of value share, owing to consumption from the arc welding segment.
Consumption of Welding Consumables in Arc Welding
Shielded metal arc welding (SMAW), also known as manual metal arc welding (MMAW) is one of the most common application of welding consumables such as stick electrodes. The extensive use of a stick electrode rod having compatibility flux with base materials provides a layer of slag that protects the welding area from atmospheric pollution. The use of stick electrode welding consumables is relatively higher in SMAW processes, compared to the rest. The core of stick electrode serves the purpose of filling material and lower the welding costs by prevent the use of additional filler metals. The only factor limiting the consumption of stick electrodes in their frequent replacement in order to chip off the slag settled during the SMAW process. Construction of buildings is among the most profitable application of using stick electrodes in SMAW process. In 2016, the building and construction segment of the global welding consumables market is expected to procure nearly 17% of the market value share.
Flux-cored wires are also among the widely-used welding consumables in arc welding. Flux-cored arc welding (FCAW) uses fine metal tubes containing powdered flux materials, to generate atmospheric protection during welding. The use of long flux-cored wires aids the need for high-speed welding tasks in industrial sectors, where time-consuming welding may lead to undue delay.
The use of SAW wires in submerged arc welding boosts the productivity of arc welding processes. It supplements the quality of arc welding, and the residual slag gets easily separated by itself. Moreover, the higher weld deposition as well as the lower smoke emission promotes the consumption SAW wires and fluxes as welding consumables in automation of arc welding processes.
Additional information on such research findings can be availed at here.